Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Pig Launcher / Receiver Valve Position Monitoring
Reduced misalignment risk and fewer manual verification trips
Valve position
Quick Overview
| Problem | Valve position at pig launcher and receiver stations is critical for safe pigging operations, but is not always continuously verified. |
| Solution | SENSAiO valve position sensors provide continuous monitoring of valve status (open/closed) during pigging sequences. |
| Value | Improved operational visibility, supporting correct valve sequencing and reducing risk of configuration errors. |
| ATEX | Suitable for hazardous pipeline environments (Zone 1–2), compliant with ATEX / IECEx requirements. |
The Operational Challenge
Pig launcher and receiver stations are used to insert and retrieve pipeline inspection or cleaning tools (pigs).
These operations require strict valve sequencing to ensure:
- Proper isolation of the launcher barrel
- Safe pressurization and depressurization
- Controlled flow direction through the pipeline
Incorrect valve configuration can lead to:
- Improper pig launching conditions
- Pressure imbalance within the launcher
- Risk of equipment damage or operational disruption
In many cases, valve status is:
- Verified manually by operators
- Not continuously monitored during the entire operation
- Not centrally recorded for traceability
This creates potential gaps in operational awareness, especially during complex or multi-step pigging procedures.
Why Valve Position Monitoring Matters
Valve position is a discrete but critical parameter in pigging operations.
Monitoring valve status enables:
- Verification that valves are in the expected position before and during operations
- Detection of unintended valve movements
- Traceability of valve sequences over time
- Correlation between valve position and pressure behavior
Typical interpretations include:
- A valve indicated as open when it should be closed may indicate operational error
- Unexpected change in valve position may correlate with manual intervention or mechanical issue
- Inconsistent valve sequences may affect pig movement or pressure conditions
Continuous monitoring helps ensure that valve configuration aligns with operational procedures.
SENSAiO Solution
SENSAiO deploys wireless valve position sensors installed directly on valves at pig launcher and receiver stations.
These sensors detect valve position (e.g., open / closed) and transmit status via LoRaWAN to a centralized monitoring platform.
The system provides:
- Real-time valve position visibility
- Historical logs of valve state changes
- Alerts when valve position deviates from expected configuration
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not actuate or control valves
- It does not enforce operational procedures
- It does not replace safety interlocks or control systems
The system supports operational verification and traceability.
Results and ROI
ATEX Compliance and Safety
Pig launcher stations are typically located in hazardous environments due to the presence of hydrocarbons. SENSAiO sensors:
- Are available with ATEX / IECEx certification for Zone 1–2
- Are designed for outdoor and harsh environments
- Meet requirements for installation in classified areas
All equipment is delivered with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace procedural controls, interlocks, or emergency shutdown systems.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Integration with SCADA and pipeline operation systems |
| Deployment | Suitable for retrofit on existing valves without major modification |
FAQ - Common Questions
Are Sensa.io sensors compatible with any gateway or network?
What ATEX certifications apply to Sensa.io devices?
All hazardous-area models are certified Ex II 2 G Ex ia IIC T4 Gb and IECEx approved for Zones 0–2.
What is the typical battery life?
Up to 10 years at 15-minute intervals, depending on signal strength and environment.
How are the sensors integrated into existing systems?
Through standard protocols — LoRaWAN, Modbus, MQTT, REST API — no proprietary middleware needed.
How does predictive maintenance reduce OPEX?
Early anomaly detection reduces emergency interventions by 30–40 %, extends equipment life and lowers energy costs.
What does the Sensa.io Valve Position Sensor actually measure?
The device detects real-time valve position states—open, closed, or intermediate—with high accuracy. It continuously sends this information wirelessly to your monitoring dashboard.
Can this sensor detect partial valve movement or stuck valves?
Yes. The sensor identifies irregular patterns such as partial movement, delayed response, or stuck valves, enabling early maintenance before failure occurs.
Is this sensor suitable for manual, motorized, and actuated valves?
Yes. It supports a wide range of valve types including ball, gate, butterfly, actuator-driven, and manual valves.
How fast does it update the valve position?
You can configure the reporting interval—from seconds to minutes—depending on your operational and battery needs.
How long does installation take?
Most installations take under 10 minutes. The sensor mounts using brackets or clamps without modifying existing valves.
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Trusted by a Worldwide Network
With partners in over 20 countries, SENSAiO delivers rugged sensor solutions to the toughest environments — everywhere.
